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MIG 300GD WLEDING MACHINE
USER MANUAL
Preface
This manual includes hardware description and operation introduction of MIG 300GD equipment. For
your and other people’s safety, please read the manual carefully.
Pay attention
Pay attention to the words after the signs below.
Sign
Description
The words after this sign means there is great potential danger,
which may cause major accident, damage or even death, if it is not
followed.
The words after this sign means there is some potential danger,
which may cause hurt or property lose, if it is not followed.
The words after this sign means there is potential risk, which may
cause equipment fault or break, if it is not followed.
Version
Version YF-41H, A1, Released at 19th, 7, 2012.
The contents of this manual are updated irregularity for updating of product. The manual is only used
as operation guide, except for other promises. No warranties of any kind, either express or implied
are made in relation to the description, information or suggestion or any other contents of the
manual.
CONTENTS
1 SATETY WARNING ........................................................................................................................ 4
2 Product .......................................................................................................................................... 10
2.1 General ................................................................................................................................. 10
2.2 Technical data ........................................................................................................................ 11
3 Installation ..................................................................................................................................... 12
4 Operation ...................................................................................................................................... 15
4.1 Front panel layout ................................................................................................................. 15
4.2 Operation instruction ............................................................................................................ 16
4.3 Welding environment and safety .......................................................................................... 22
4.4 Welding problems and resolution ......................................................................................... 23
5 Daily maintenance and checking .................................................................................................. 24
6 Trouble shooting and fault finding ................................................................................................. 28
Appendix
Welding parameter list .................................................................................................. 32
Appendix
Circuit diagram .............................................................................................................. 35
Appendix
Components figure and list ........................................................................................... 36
3
1
SATETY WARNING
The safety notes listed in this manual is to ensure correct use of the machine and to keep you
and other people from being hurt.
The design and manufacture of welding machine considers safety. Please refer to the safety
warning listed in the manual to avoid accidents.
Different damage would be caused by wrong operation of the equipment as follows. Please
read the user manual carefully to reduce such damage.
Sign
Description
Any contact of electric parts may cause fatal electric shock or burnt.
Gas and fumes are harmful to health.
Operation in narrow space may cause choke .
Spark and hot workpiece after welding may cause fire.
Bad connected cable may cause fire.
Incompletion connection of workpiece side circuit may cause fire.
Never weld on the case of tinder stuff, or it may cause explode.
Never weld airtight containers such as slot, pipe etc., or it may break.
Arc ray may cause eye inflammation or skin burnt.
Spark and residue will burn your eyes and skin.
Toppling over of the gas cylinder will cause body hurt.
Wrong use of the gas cylinder will lead to high-pressure gas eruption
and cause human hurt.
Never let fingers, hair, clothes or etc. near the moving parts such as
the fan.
The wire shoot out of the torch may stab eyes, face and other naked
parts.
Never stand in front of the swang equipment or under it, or it may fail
and cause injury.
4
Please follow the rules below to avoid heavy accidents.
● Never use the equipment to do other things but welding.
● Follow related regulations for the construction of the input-driven power source, choice of
place, usage of high-pressure gas, storage, configuration, safe-keeping of workpiece after
welding and disposal of waste, etc.
● Nonessentials do not enter the welding area.
● People using heart pacemaker is not allowed to get close to the welding machine or area
without doctor’s permission. The magnetism created by energizing the welding machine
can have a bad effect to the pacemaker.
● Install, operation, check and maintain the equipment by profession personnel.
● Understanding the contents of the user manual for safety.
Please follow the rules below to avoid electric shock
● Keep away from any electric parts.
● Earth the machine and workpiece by professional personnel.
● Cut off the power before installation or checking, and restart 5 minutes later. The
capacitance is chargeable device. Please ensure it has no voltage before start again even if
the power source is cut off.
● Do not use wire with inadequate section surface or damage insulation sleeve or even
exposed conductor.
● Do ensure well isolation of wire connection.
● Never use the device when the enclosure is removed.
● Never use broken or wet insulation gloves.
● Use firenet when work at high position.
● Check and maintain regularly, don’t use it until the broken parts are fixed well.
● Turn off the power when not in used.
● Follow the national or local related standard and regulations when using the AC welding
machine at narrow or high position.
Please follow the below notes to avoid fire and explode, etc.
● No combustible in welding area.
● Keep off combustible when welding.
● Keep hot workpiece after welding away from flammable gas.
● Do move away the combustible around when weld the dooryard, ground and wall,.
● The wire connection of base metal should be as close to the welding place as possible.
● Never weld those facilities with gas pipe or airtight slot.
● Put fire extinguisher around the welding area to prevent fire.
5
The gas and fumes are harmful to health, please wear protective
device according to regulations.
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Wear exhaust equipment and breathe preventive facilities to prevent gas poisoning or
choke.
Use suggested part exhaust equipment and breathe preventive facilities to prevent hurt or
poisoning by gas and other powder, please.
To prevent oxygen-deficiency, air out the gas-filled room which is full of CO2 and argon on
the bottom, When operating on trunks, boilers, cabins, etc.
Please accept the supervisor’s inspection when operating in narrow space. Air the room
and wear breathe preventive facilities.
Never operate in degrease, washing or spray space.
Using breathe preventive facilities when weld shielded steel for it will cause poisonous dust
and gas.
The arc, spark, residue and noise are harmful to health, please wear
protective appliance.
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●
●
Eye protection against arc is recommended when welding or supervise welding.
Please wear preventive spectacles.
Welder’s gloves, welder’s goggles, long sleeve clothes, leather apron, and other standard
protection equipments must be worn for welding operation.
●
A screen to protect other people against the arc must be set in the welding place.
Please follow the notes below to avoid gas cylinder toppling over or
broken.
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6
Use the gas cylinder correctly.
Use the equipped or recommended gaseous regulator.
Read the manual of gaseous regulator carefully before using it, and pay attention to the
safety notes.
Fix the gas cylinder with appropriative holder and other relative parts.
Never put the cylinder under high temperature or sunshine environment.
Keep your face away from the gas cylinder exit when opening it.
Put on the gas shield when it is not used.
Never put the torch on the gas cylinder. The electrode can not meet the gas cylinder.
Any touch of the switch part will cause injury, please note the
following.
● Never use the machine when the enclosure is off.
● Install, operate, check and maintain the machine by professional person.
● Keep your fingers, hair, clothes etc. away from the switch parts such as the fan.
The wire end may deal damage, please note the following.
● Never look into the electric conduction hole when checking the wire feeding is normal or
not, , or the shooting wire may stab your eyes and face.
● Keep your eyes, face or other naked parts away from the end of torch when feeding the wire
manually or pressing the switch.
For better work efficiency and power source maintenance, please
note the following.
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●
●
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Precautions against toppling over.
Never use the welding equipment for pipe thawing.
Lift the power source from side when use the up-down forklift truck to avoid toppling over.
When using the crane for lift, tie the rope to the ears with an angle no more than φ15 to the
vertical direction.
When lifting the welding machine which equipped with gas cylinder and wire feeder,
download them from the power source and ensure the horizontal of the machine. Do fix the
gas cylinder with belt or chain when moving it to avoid body hurt.
Ensure fastness and insulation when lifting the wire feeder through the swing ring for
welding.
7
Correct
False
Lifting way for gas shielded machines
Electromagnetic interference needing attention:
●
●
It may need extra preventive measures when the equipment is used in particular location.
Before the installation, please estimate the potential electromagnetism problems of the
environment as follows.
a) Upper and lower parts of the welding equipments and other nearby power cable, control
cable, signal cable and phone cable.
b) Wireless electric as well as TV radiation and reception equipment.
c) Computer and other control equipments.
d) Safety-recognition equipment etc. Such as supervise of industrial equipments.
e) Health of people around. Such as personnel using the heart pacemaker or audiphone.
f) Equipments for adjustment and measurement.
g) Anti-disturb capability of other used equipments .Users should ensure these equipments
and the environment are compatible, which may need extra preventive measures.
h) Practical state of the welding and other activities.
8
●
Users should observe the following dos and don’ts to decrease radiation interference.
a) Connect the welding equipments to the power supply lines.
b) Maintain the welding equipments regularly.
c) The cable should be short enough to be close to each other and the ground.
d) Ensure the safety of all the welding metal parts and other parts nearby.
e) The workpiece should be well earth.
f) Shield or protect the other cable and equipments to decrease the effects of disturbances.
The welding equipments can be complete shielded in some special conditions.
●
Users are responsible for interference due to welding.
9
2
Product
2.1 General
The welding machine applies the most advanced inversion technology in the world.
The principle of inversion is to transform the power frequency of 50Hz/60Hz into direct current
and invert it into high frequency (24KHz) through high-power device IGBT, then perform
voltage-drop and commutation with the output high-power D.C power supply via Pulse Width
Modulation (PWM). Since the switch power inversion technology is adopted, the weight and
volume decrease greatly while the conversion efficiency increase of more than 30%
Additional to MIG, the machine added MMA function. It adopts full digital panel display, which
can realize synergic adjustment of feeding speed and welding voltage as well to regulate the
welding parameters easily.
Our CO2 gas shielded welding machine is equipped with unique electronic reactor circuit, which
can precisely control the short-circuiting transfer and mixed transfer resulted in better
performance than other machines. Compared with silicon controlled welding machine and
tapped welding, our products have the following advantages: stable wire feed rate, portable,
energy-saving, electromagnetic noise free. Besides, our products spatter less, easier arc
starting, deep welding pool, high duty cycle etc.
With high-efficiency and electrical-saving advantage, this equipment is applicable for both
multi-metal and mutli-technology required welding.
Thank your for choosing our products. Please feel free to propose your valuable suggestions;
we will make efforts to perfect our products and service.
The machine is mainly used in industrial fields. It will cause radion interference if used
indoors. Please take through precaution measures.
10
2.2 Technical data
Type
Item
Power voltage (V)
Frequency (Hz)
MIG 300GD
3 phase
380V 15%
50/60
Rated input current (A)
MMA
MIG
18.5
16.8
Output current adjustment (A)
MMA
MIG
40-300
45-300
Output voltage (V)
MMA 21.6-32
MIG 16.2-29
Duty cycle (%)
35
Power factor
0.93
Efficiency (%)
85
Type of wire feeder
Internal
Wire feed speed (m/min)
2.2-15
Post flow time (S)
3
Welding-wire diameter (mm)
0.8/1.0/1.2
Insulation grade
F
Housing protection grade
IP21
Welding thickness (mm)
More than 0.8
Weight (kg)
Overall dimension (mm)
60
595*275*520
11
3
Installation
The welding equipment is equipped with power voltage compensation device. It keeps the
machine work normally when power voltage fluctuating ±15% of rated voltage.
When using long cable, in order to reduce voltage drop, big section cable is suggested. If the
cable is too long, it will affect the performance of arcing and other system function, it is
suggested to use the recommend length.
Make sure the intake of the machine is not covered or blocked to avoid the malfunction of
the cooling system.
Use ground cable whose section no less than 6mm 2 to connect the housing and earth. The
method is to connect the grounded interface in the back to the earth device, or make sure
the earth end of power interface has been reliably and independently grounded. Both ways
can be used together for better security.
MIG 300GD Installation Procedures
Correct Installation of MIG
a)
b)
c)
d)
e)
f)
g)
h)
Connect the gas cylinder with CO2 decompression flow mete tightly to CO2 mouth behind
the machine via air tube.
Insert the swift plug of earth cable into socket at the front panel.
Set the wire wheel with wire on the wheel axis, the wheel hole should be matched with the
wheel fixer.
Choose wire slot according to wire size.
Loosen the screw of wire-pressing wheel, pit the wire into slot via wire-lead tube, adjust the
wire-pressing wheel to keep wire fix from gliding, but strength should be suitable in case the
wire distorts and affects wire sending.
Wire roll should turn clockwise rotation to let out wire, to prevent wire from gliding; wire is
usually set to the fixed hole on the wheel side. To prevent the bent wire from getting stuck,
please cut off this part of the wire.
Put and tighten the torch on the output socket and put the wire into the torch by hand.
Put the heater plug of the gas meter to the heater socket on the back panel.
Correct Installation of MMA
a)
b)
c)
12
Make sure cable with electrode holder and quick plug connected well. Connect the quick
plug to the socket “-” of the machine, and fasten it clockwise tightly.
Connect the quick plug at one end of the cable into the socket “+” of the machine, and
fasten it clockwise, the other end clamps the workpiece.
Please pay attention to the connecting terminal, DC welding machine has two connecting
ways: positive connection and negative connection. Positive connection: holder connects
with “-” terminal, while work piece with the “+” terminal. Negative connection: work piece
with the“-” terminal, holder with the “+” terminal. Choose suitable way according to the
working situation. If unsuitable choice is made, it will cause unstable arc, more spatters and
conglutination. If such problems occur, please change the polarity of the fastened plug. It
should adopt negative connection when welding with alkaline electrode, while positive
connection when welding with acid electrode.
This procedure shall be operated by electrician!
Connect proper power cable to the distribution box with corresponding capacity according to the
input voltage and current (See technical parameter table). Do not connect to the inappropriate
voltage and make sure that the difference of power supply is within permitted range.
13
Installation drawing of MIG 300GD (MIG):
Installation drawing of MIG 300GD (MMA):
14
4
Operation
4.1 Front panel layout
9
1
8
7
2
6
3
5
4
Front panel instruction
1
MMA/MIG switch key
2
VRD/2T/4T switch
key
φ1.0mm
φ1.2mm)
3
Wire diameter selection key(φ0.8mm
4
Data selection key (effective under MIG mode)
5
Store mode selection key(Memory1
6
Multifunctional data adjusting knob coarse adjustment by pressing the knob and turning it:
big regulating rate and high speed; fine adjustment only by turning the knob: small
regulating rate and low speed
7
Gas check
Memory2 Memory3)
15
8
Multifunctional data
display 9
Burn back
Polarity conversion joint
This machine has the polarity conversion; There are positive output terminal and negative
output terminal between wire feeder and wire spool; When use solid wire with gas protection,
torch socket should be connected to the positive output terminal, ground cable should be
connected to the negative output terminal; When use flux-cored wire, the two connected cable
should be exchanged.
4.2 Operation instruction
4.2.1 Welding display
The starting up display
Switch on the welding power source, the front panel displays as Chart 1. After the
Multifunctional data display (or any key or knob on front panel) flashes for 5 seconds, the
machine enters into the welding mode that saved in the last shutdown.
Chart 1: the starting-up display interface
Operation instruction under MMA mode.
a)
b)
16
When welding stops, Press the STICK/LIFT TIG/MIG switch key the STICK indicator
lights up and it turns into STICK mode.
When under STICK mode, pressing the
VRD/2T/4T switch key , VRD function is
enabled when the indicator lights up, and displays in multifunctional data display . Or,
the VRD function isn’t enabled if the indicator is off. (Chart 2, Chart 3)
Chart 2: under MMA mode, preset current
Chart 3: under MMA mode preset current
display with VRD enabled
c)
d)
e)
f)
display VRD disabled
multifunctional data display shows the preset current“080A”, its unit is ampere(A).
Adjusting the Multifunctional data adjusting knob can change the welding current during
welding process, and displayed in
multifunctional data display . The welding current
range is 10A-300A.
3 seconds later after setting the welding parameters, the
multifunctional data display
would flashes for one time, which means the data has been saved.
The panel displays as Chart 4 when perform welding, which means the welding voltage is
23.2V, and the preset current 80A. 5 seconds later, it returns to the preset current state.
Chart4: The display status when welding under MMA mode.
Operation instruction under MIG mode.
a)
When welding stops, press MMA/MIG switch key
MIG indicator lights up, and the
machine enters into MIG mode.(Chart 5)
b)
multifunctional data display shows the preset voltage “18.0V”, its unit is volt(V). while
“05.0m/min means the preset wire feeding speed, its unit is m/min”
17
c)
Under MIG mode, pressing BURN BACK ,the indicator lights up, which can realize high
speed wire feeding(Chart 6). multifunctional data display would flash continuously until
pressing the torch switch or any key or knob on the panel. Both
multifunctional data
display and BURN BACK stops flashing, and the wire stops feeding.
Chart 5: Preset voltage display under MIG mode
d)
Chart 6: Burn back display under MIG mode
Under MIG mode, press the
Gas check ,the indicator lights up, which can realize gas
check function(chart 7).
multifunctional data display would flash continuously until
pressing the torch switch or any key or knob on the panel. Both
multifunctional data
display and GAS CHECK stops flashing, and the gas stops checking.
Chart 7: Gas check display under MIG mode
e)
Under MIG mode, operate
VRD/2T/4T switch key to choose the welding mode. 2T
NORMAL lighting up means 2 step control way: press the torch switch, feed the gas in
advance, and perform welding normally; release the torch switch, burn back and get rid of
the ball on the end of wire, then stop feeding gas 3 seconds later. While, 4T LATCH
lighting up means 4 step control way: press the torch switch for the first time, feed the gas
in advance, and ignite the arc to perform welding; then release the torch switch and
perform welding normally. Press the torch switch for the second time, the welding current
18
attenuates until to crater value and keep on, then release the torch switch again, burn
back and get rid of the ball on the end of wire, then stop feeding gas 3 seconds later.
f)
g)
h)
Under MIG mode, operate the
wire diameter selection , choose different wire diameter
among φ0.8mm φ1.0mm φ1.2mm
Adjust Multifunctional data adjusting knob during welding can realize the synergic
manipulation of welding voltage and feeding speed, which displays in multifunctional data
display . Theφ0.8mm wire adjustable range is 16.2V 3.0m/min 27V 15.0m/min;φ1.0mm
wire adjustable range is 16.5V 2.2m/min 30.3V 12m/min;φ1.2mm wire adjustable
range is 18.1V 2.2m/min 29.4V 9.0m/min.
Press the data selection key for the first time, the multifunctional data display displays
as Chart 8, which means the welding voltage is adjustable, and the adjustment range of
preset voltage is ±20%; Press the data selection key
for the second time, the
multifunctional data display
displays as Chart 9, which means the inductance is
adjustable, and its adjustment range is ±10%; Press the data selection key for the third
time, it would turn back to preset welding voltage and wire feeding speed.
Chart 8
fine adjustment display of voltage
Chart 9 Fine adjustment display of
Inductance presetting range under MIG mode
i)
j)
k)
3 seconds later after setting the welding parameters, the
range under MIG mode
multifunctional data display
would flashes for one time, which means the data has been saved.
The panel displays as Chart 10 when perform welding, which means the welding voltage is
18.2V, and the current is 82A.
Releasing the torch switch and stopping welding, the panel displays as Chart 11.
Moreover,“HOLD” flashes for 3 seconds and quenched, which means the welding stops. 2
seconds later, multifunctional data display redisplays the preset current.
19
Chart 10 display status when perform welding under
Chart 11 Display status after stop
welding under MIG mode
MIG mode
Storage function
Press
mode selection , can store 3 modes, which are Memory1,Memory2 and Memory3.
4.2.2 Malfunction display
Malfunction display of wire feeder
The panel displays as Chart 12 when the wire feeder is malfunctioning, and the
multifunctional data display flashes continuously, the machine can not work normally.
Please restart the machine, the panel would display the parameters that were set before
malfunction occurrence.
Malfunction display of over-current
The panel displays as Chart 13 when over-current, and the
multifunctional data display
flashes continuously, the machine can not work normally. Restart the machine, the panel
would display the parameters that were set before malfunction occurrence.
20
Chart 12 malfunction display of wire feeder
Chart 13
Malfunction display of over current
Malfunction display of overheating protection
The panel displays as Chart 16 when overheating, and the
multifunctional data display
flashes continuously, the machine can not work normally. Only when the temperature of the
welding machine falls below 60 , the overheating malfunction would disappear, and the
machine work normally without restarting.
Chart 14 Malfunction display of overheating protection
21
4.3 Welding environment and safety
Environment
a)
b)
c)
d)
The machine can perform in environment where conditions are dry with a dampness level
of max 90%.
Ambient temperature is between -10 to 40 degrees centigrade.
Avoid welding in sunshine or drippings. Do not let water enter the gas
Avoid welding in dust area or the environment with corrosive gas.
e)
Avoid gas welding in the environment with strong airflow.
Safety norms
Our welding machine has installed protection circuit of over voltage, over current and over
heat. When voltage, output current and temperature of machine are exceeding the rate
standard, welding machine will stop working automatically. Because that will be damage to
welding machine, user must pay attention to following.
a)
The working area is adequately ventilated
Our welding machine is powerful machine, when it is being operated, it generated by high
currents, and natural wind can’t be satisfied with machine cool demands. So there is a fan
in inter-machine to cool down machine. Make sure the intake is not in block or covered, it is
0.3 meter from welding machine to objects of environment. User should make sure the
working area is adequately ventilated. It is important for the performance and the longevity
of the machine.
b)
Do not over load
The operator should remember to watch the max duty current (Response to the selected
duty cycle).Keep welding current is not exceed max duty cycle current. Over-load current
will damage and burn up machine.
c)
No over voltage
Power voltage can be found in diagram of main technical data. Automatic compensation
circuit of voltage will assure that welding current keeps in allowable range. If power voltage
is exceeding allowable range limited, it is damaged to components of machine. The
operator should understand this situation and take preventive measures.
d)
22
There is a grounding screw behind welding machine, with a grounding marker on it. Before
operation, welding crust must be grounded reliable with cable which section is over 6
square millimeters, in order to prevent from static electricity, and accidents because of
electricity leaking.
4.4 Welding problems and resolution
The phenomenon listed below may happen due to relevant accessories used, welding material,
surroundings and power supply. Pleas improve surroundings and avoid these problems..
Arc starting difficulty. Arc interruption happens easily:
a)
b)
Examine whether grounding wire clamp contacts with the work pieces well.
Examine whether each joint has improper contact.
The output current fails to reach rated value:
The deviation of power voltage from rated value may cause that the output current does no
accord with adjusted value. When the power voltage is lower than rated value, the
maximum output current may be lower than rated value.
The current can not keep stable during operation:
This situation may relate to the following factors:
a)
The voltage of electric power network changes;
b)
Serious interference from electric power network or other electric facilities.
Gas vent in welds:
a)
Examine whether the gas supply circuit has leakage.
b)
Examine whether there is sundries such as oil, dirt, rust, paint etc. on the surface.
23
5
Daily maintenance and checking
Daily maintenance
a)
b)
c)
d)
e)
f)
Remove dust regularly with dry compressed air. If the welding machine is used in
surroundings with heavy smoke and polluted air, it is necessary to remove dust at least one
time one month.
The pressure of compressed air shall fall to required level to prevent damage to small
components in the machine.
Examine inside electric joints and ensure perfect contact (Especially plugs and sockets).
Fasten the loosing joints. In case of oxidation, remove oxide film with sand paper and
connect again.
Prevent water from entering into the machine and prevent the machine from getting moist. If
any, blow and dry. Measure the insulation with megohmmeter to make sure it is qualified to
use.
If the welding machine is not used for a long time, pack the machine in original package and
store in dry surroundings.
Every time the wire feeder operates for 300hours, grind the electrical carbon brush and
clear up the armature commutator. Rinse speed reducer, apply 2# Molybdenum Disulfide
lubricant to the turbine, whirlpool rod and bearing.
The power shall be cut off completely before all maintenance, repairing works. Make sure
to pull out power plug before opening the case.
24
Daily checking
WELDING POWER SUPPLY
Position
Control panel
Cooling fan
Power part
Periphery
Checking keys
Remarks
Switch condition of operation, transfer and
installation.
Test the power indicator.
Check if there is wind and the sound normal
or not.
If abnormal noise
and no wind, to
check the inner.
When electrified, abnormal smell or not.
When electrified, abnormal vibration and
buzz or not.
Color changing and heating or not in
appearance.
Gas pipe broken, loosen or not.
Housing and other fixed parts loosen or not.
WELDING TORCH
Position
Checking keys
If installment fixed, the front
distorted
Remarks
Reason for air hole.
Loophole
Electric hole
Attach splash or not.
Reason for burning the torch.
can use splash-proof material
If installment fixed
Reason of torch screw thread
damage
Damage of its head and
hole blocked nor not
Check the extended size of
the pipe
Wire sending
tube
Wire diameter and the tube
inner diameter match or not
Reason of
broken arc
unstable
arc
and
Have to be changed when less
than 6mm, when the extended
part too small, the arc will be
unstable.
Reason of unstable arc, please
use the suitable tube.
25
Partial
extended
winding
and
Block caused by dirt in the
tube, and the remains of the
wire plating lay.
Wire sending tube broken O
circle wear out
Gas bypass
Forget to insert or the hole
blocked, or different factory
component.
Reason of poor wires sending and
unstable arc, please change.
Reason of poor wire sending and
unstable arc, (use kerosene to
wipe or change new one.)
1.Pyrocondensation tube broken,
change new tube
2.Change new O circle
May lead to vice (splash) because
of poor gas shield, torch body get
burned (arc in the torch), please
handle.
WIRE SENDING MACHINE
Position
Pressing
arm
Checking keys
Remarks
If put the arm to the suitable indicating
level. notes not to damage wire less
than Ф1.2mm
If powder or residue store up in the mouth
of the tube.
Wire
lead
tube
Wire diameter and
diameter match or not
the
tube
inner
If the tube mouth center matches the wire
wheel slot center or not.
Wire
wheel
Pressure
wheel
26
Wire diameter matches the wheel’s
requirement
If the wheel slot blocked.
Check the stability of its move, and
wearing-out of pressed wire, the narrowing of
its contact surface
Lead to unstable arc and
wire sending.
Clean the residue and
check the reason and solve
it.
If not match, lead to
unstable arc and residue.
If unmatched, lead to
unstable arc and residue.
Lead to unstable arc
and
residue,
and
block wire tube.
Change new one of
necessary.
Lead to unstable arc and
wire sending.
CABLE
Position
Torch
cable
Output
cable
Input
cable
Earth
cable
Checking keys
If torch cable over bended.
If the metal connecting point of mobile plug
loosen.
Wearing-out of the cable insulated material.
Cable connecting head naked(insulation
damage),or loosen(the end of power supply,
and cable of main material connecting point.)
If the connect of power supply input, protective
equipment input and the output end fixed or not.
If the security equipment cable reliably
connected.
If the power input end cable fixed.
If the input cable is worn out and bares the
conductor.
If the earth cable that connects the power
supply is broken and connect tightly.
If the earth cable that connects the main part is
broken and connects tightly.
Remarks
Cause poor wire
sending.
Unstable arc if
cable over bended.
For life security and
stable welding, adopt
suitable method to
check according to
working place.
Simple
check
daily
Careful and
in-depth check
on fixed period
To prevent creep age
and insure security,
please make daily
check.
27
6
Trouble shooting and fault finding
Notes: The following operations must be performed by qualified electricians with valid
certifications. Before maintenance, you are suggested to contact local distributor to
verify qualification.
Malfunctions and solutions of MIG 300GD:
Malfunctions
The meter show nothing;
Fan does not rotate;
No welding output
The meter shows;
Fan works normally;
No welding output
the meter shows;
Solution
1.
2.
3.
4.
Confirm the power switch is on.
Power supply available for input cable.
Check if the commute bridge is damaged.
There is malfunction occurs in the supplementary power
source on control board (contact dealers).
1. Check if all the sockets in the machine are connected well.
2. There is open circuit or badness of connect at the joint of
output terminal.
3. The control cable on the torch is broken off or the switch is
damaged.
4. The control circuit is damaged.(contact to dealers)
1. It might be over-current protection, please turn off the power
switch; restart the machine after the abnormal indicator light
winked.
Fan works normally;
Abnormal indicator lights.
2. It might be overheating protection, please wait for about 2-3
minutes until the machine renew without turn off the power
switch.
3. It might be multifunction of inverter circuit. (contact dealers)
28
INITIAL PROBLEMS DIAGNOSE
Even the machine comes up with abnormal phenomenon such as welding unable, arc unstable
or bad welding effect, it is still early to judge that there is malfunction on the machine.
The above-mentioned abnormal phenomenon may be caused by some reasons. For example:
tight parts loosen, forgetting to switch on, wrong set up, cable broken and gas rubber pipe
cracked, etc. Therefore, please test and inspect these factors before deliver it back to the factory
because a large number of troubles may be easily solved probably.
For this reason, an initial diagnosis list for general welding troubles is shown below. A trouble
happened may be found in the column of “Abnormal items” on up-right of the list, please inspect
and maintain for the corresponding items which have “ " mark in the column according to the
following list respectively.
Initial problems diagnose
Blowhole Formed
Wire Stick to Conductive Tip
Wire Stick to Parent material
Dirt on Edge of Weld Seam
Unstable Arc
Bad Arc Ignition
No Wire Feeding
No Gas out
Area and Item to be Inspected and Maintained
No arch Arc Starting
Abnormal Items
1. Turn on power supply or not?
Distribution Boxes
(Input Protection
Devices)
2. Fuse burnt out
3. Connection joint loose
1. Examine whether the cable is cut
off.
Input Cable
2. Connection joint loose
3. Over heat
Welding Power
Operation
1. Turn on power supply or not?
2. Phase Lacking
29
1. Turn on gas supply
2. Residual Amount of Gas in the
Gas Cylinder and
Gas Regulator
Cylinder
3. Set value for flow
4. Connection joint loose
Gas supply hose
(the whole line from
the high pressure
cylinder to the weld
gun)
1. Connection joint loose
2. Gas hose damaged
Initial problems diagnose
Blowhole Formed
Wire Stick to Conductive Tip
Wire Stick to Parent material
30
2. Adaptability of conductive tip, wire feeding
pipe and cable diameter Worn, blocked up or
deformation, etc.
Dirt on Edge of Weld Sea
Weld Gun and
Cable
Unstable Arc
1. Weld gun cable rolled up or over curved
Bad Arc Ignition
Wire Feeding
Device
1. Wire feeding wheel does not match with
the diameter of wire in texturing tube
2. Crackle on wire feeding wheel, groove
blocked up or defect
3. Too tight or loose of the handle
4. Wire powder accumulated on the inlet of
SUS pipe
No Wire Feeding
Area and Item to be Inspected and Maintained
No Gas out
No arch
Abnormal Items
Body of weld gun
Power supply
cable of weld gun
as well as cable of
switch control
Surface Condition
of Parent material
and length that
wire stretches out
Output Cable
1. Loose connection of conductive tip, nozzle
and nozzle contactor
2. Contactor of weld gun body is not plunged
in or tightened well
1. Break off (bending fatigue)
2. Damaged by weighted drop
1. Oil, dirty, rust and paint residues
2. Too long length of wire stretched out
1. Cross-section of cable that connects to
parent material is not enough
2. Loose connection of （+）（
, -）output cable
3. Bad electric conductivity of parent material
Lengthened
Cable
Work Condition
for Welding
1. Cross-section of cable is not enough
2. It is rolled up or folded
Welding current, voltage, angle of weld
gun, welding rate and wire length
stretched out should be confirmed once
again
31
Appendix
Welding parameter list
Generally, welding current is adequate to welding electrode according with as
following.
Electrode
specification
φ2.5
φ3.2
φ4.0
φ5.0
Welding current
70-100A
110-140A
170-220A
230-280A
Welding variables when use MIG welding
The values listed in the following table are the general specification values under standard
condition.
Plate
Wire
thickness
diameter
Interval
(mm)
mm
Low welding speed
I Square butt welding
High welding speed
32
Current
A
Voltage
Welding
Wire
speed
extension
V
(mm)
Gas flow rate
(L/min)
(cm/min)
(mm)
0.8
0.8,0.9
0
60 70
16 16.5
50 60
10
10
1.0
0.8,0.9
0
75 85
17 17.5
50 60
10
10 15
1.2
0.8,0.9
0
80 90
16 16.5
50 60
10
10 15
1.6
0.8,0.9
0
95 105
17 18
45 50
10
10 15
2.0
1.0,1.2
110 120
18 19
45 50
10
10 15
2.3
1.0,1.2
0.5 1.0
120 130
19 19.5
45 50
10
10 15
3.2
1.0,1.2
1.0 1.2
140 150
20 21
45 50
10 15
10 15
4.5
1.0,1.2
1.0 1.5
160 180
22 23
45 50
15
15
1.2
1.2 1.6
220 260
24 26
45 50
15
15 20
1.2
1.2 1.6
220 260
24 26
45 50
15
15 20
1.2
1.2 1.6
300 340
32 34
45 50
15
15 20
1.2
1.2 1.6
300 340
32 34
45 50
15
15 20
0.8
0.8,0.9
0
100
17
130
10
15
1.0
0.8,0.9
0
110
17 5
130
10
15
1.2
0.8,0.9
0
120
18 5
130
10
15
1.6
1.0,1.2
0
180
19 5
130
10
15
2.0
1.0,1.2
0
200
21
100
15
15
2.3
1.0,1.2
0
220
23
120
15
20
3.2
1.2
0
260
26
120
15
20
0
0.5
Plate
Wire
thickness
diameter
Current
Voltage
A
V
Fillet
butt
welding
mm
mm
1.6
0.8,0.9
60 80
2.3
0.8,0.9
3.2
Welding
Wire
speed
extension
Gas flow rate
L/min
cm/min
mm
16 17
40 50
10
10
80 100
19 20
40 55
10
10 15
1.0,1.2
120 160
20 22
35 45
10 15
10 15
4.5
1.0,1.2
150 180
21 23
30 40
10 15
20 25
Plate
Wire
Welding gun
thickness
diameter
vertical
angle(°)
mm
Horizontal fillet
Low welding speed
1.0
1.2
0.8,0.9
0.9,1.0
8.9
High welding speed
butt welding T joint
12
1.0
1.2
1.6
1.0,1.2
1.2
1.2,1.6
1.2,1.6
0.8,0.9
0.8,0.9
1.0,1.2
18 19
50 60
10
10 15
100 110
19 20
50 60
10
10 15
0
115 125
19 20
50 60
10
10 15
0
130 140
20 21
50 60
10
10 15
0
150 170
21 22
45 50
15
15 20
0
140 200
22 24
45 50
15
15 20
0
230 260
24 27
45 50
20
15 20
0
270 380
29 35
45 50
25
20 25
0
400
32 36
35 40
25
20 25
0
140
19 20
160
10
15
0
130 150
19 20
120
10
15
0
180
22 23
120
10
15 20
0
210
24
120
15
20
0
230
25
110
20
25
0
270
27
110
20
25
0
290
30
80
20
25
0
310
33
70
25
25
45
45
45
45
50
50
45
45
45
1.2
45
6
1.2
L/min
85 90
2.3
1.2
mm
0
45
45
4.5
(cm/min)
10 15
1.2
1.2
rate
10
2
3.2
extension
50 60
45
1.0,1.2
speed
17 18
1.0,1.2
1.0,1.2
Gas flow
70 80
2
6
V
Wire
0
45
45
4.5
A
Welding
0
1.0,1.2
3.2
Voltage
mm
1.6
2.3
Current
45
50
50
33
Plate
Wire
Welding gun
thickness
diameter
vertical
angle(°)
Low welding speed
mm
0.8
0.8,0.9
3.2
(cm/min)
mm
L/min
80 90
18 19
45 50
10
10 15
0
90 100
19 20
45 50
10
10 15
0
100 130
20 21
45 50
10
10 15
0
120 150
20 21
45 50
10
10 15
0
150 180
20 22
35 45
10 15
20 25
0
47
200 250
24 26
45 50
10 15
20 25
470
220
24
150
15
15
470
300
26
250
15
15
47
2 3
rate
10 15
0.8,0.9
2
extension
10
30
1
speed
40 45
0.8,0.9
1.0,1.2
Gas flow
16 17
1.6
3.2
V
Wire
60 70
30
1.0,1.2
A
Welding
0
0.8,0.9
2.3
Voltage
0
10
1.2
4.5
High welding speed
Horizontal fillet welding joint
34
mm
Current
47
47
1.2
Appendix
Circuit diagram
35
Appendix
Components figure and list
Structure Chart of MIG 300GD
36
Major parts list of MIG 300GD
No.
Item
Quantity
No.
Item
Quantity
1
Air switch
29
Horizontal clapboard
2
Fuse seat
30
Erect clapboard
3
Fan cover
31
Handle
4
Supporting of radiator
32
Right cover
5
Push/lock button
33
Left upper cover
6
Socket
34
Left down cover
7
Heater board
35
Chassis of the kit
8
Absorption board
36
upper cover of the kit
9
Capacitor
37
Right cover of the kit
10
Transformer
38
Left cover of the kit
11
Reactor
39
Left supporting of the tray
12
commutate module
40
Right supporting of the tray
13
radiator
41
Handle of the kit
14
radiator
42
Supporting of the front wheels
15
Fan board
43
tray
16
Fan net
44
axis
17
Silicon single wheel
45
Negative copper connector
18
Crater
46
Radiator connect board
19
Automatic line-lock button
47
M5X30 screw
20
Discal axis(plastic)
48
Upper plastic panel
21
switch
49
Down plastic panel
22
Hinge
50
EMC insulating board
23
Main control board
51
Control board of the panel
24
Control panel
52
Socket
25
Front panel
53
Fan
26
Panel preventive cover
54
Electromagnetism valve
27
Supporting of argon cylinder
55
Wire feeder structure
28
Machine chassis
1
1
2
4
4
2
1
1
1
1
1
2
1
1
1
1
2
2
2
1
3
4
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
6
1
2
2
1
1
1
1
1
1
56
Central
switch socket
37